Construction panel

ABSTRACT

This application relates to a light-weight, multi-purpose construction panel. The panel may be formed, for example, from molded plastic. Each panel includes a substantially planar deck on a first side thereof and a second side comprising alternating male and female sleeves arranged in honeycomb-like compartments defined by a plurality of wall elements. A pair of panels may be releasably coupled together with their respective second sides facing inwardly to form a construction assembly. When a pair of panels is coupled together, the male sleeves of one panel matingly fit within the females sleeves of the other panel, and vice versa. Each panel may also include guide tubes which are aligned when the panels are coupled together. A plurality of channels may be formed in the deck on the first side of the panel and spaced-apart apertures may be arranged in the channels in alignment with the guide tubes for insertion of fasteners therein or to allow water drainage through the assembly. The wall elements may include spaced-apart notches which together define conduits extending through the interior of an assembly when a pair of panels are coupled together. The conduits are sized to receive fluid delivery tubes for delivering fluid, such as heated air or water, through the panel assemblies. The panel assemblies may be used for many different construction applications including flooring, roofing and wall structures.

RELATED APPLICATION

The application is a continuation-in-part of U.S. patent applicationSer. No. 11/746,301 filed 9 May 2007 which is hereby incorporated byreference in its entirety.

TECHNICAL FIELD

This application relates to a multi-purpose construction panel.

BACKGROUND

Modular panels may be used for many different types of constructionapplications. For example, interlocking panels may be used to formtemporary flooring, roofing or wall structures. Other potentialcommercial applications are described in applicant's co-pending U.S.patent application Ser. No. 11/689,409 filed 21 Mar. 2007 entitledMULTI-PURPOSE CONSTRUCTION MODULE, which is hereby incorporated byreference in its entirety.

There is a need for light-weight, economical construction panelsparticularly suitable for sale directly to consumers at building supplyretail outlets and the like. There is a particular need for constructionpanels which may be quickly and easily coupled together without the needfor specialized tools or skills to form a wide variety of constructionassemblies.

SUMMARY OF INVENTION

In accordance with the invention, a construction panel having a firstside and a second side is provided. The first side comprises asubstantially planar deck and the second side comprises a plurality offirst wall elements defining a plurality of compartments therebetweenand a plurality of sleeves each located in one of the compartments. Thesleeves may include a first group of female sleeves having a firstheight and a second group of male sleeves having a second heightexceeding the first height, wherein the male sleeves of one of thepanels are sized to fit within the female sleeves of another one of thepanels (i.e. when a pair of panels are coupled together with theirrespective second sides facing inwardly). The male and female sleevesmay be arranged in an alternating array on the second side of eachpanel.

In one embodiment, at least some of the wall elements may includenotches formed on an edge portion thereof. When a pair of panels arecoupled together to form a construction assembly, the notches togetherdefine a conduit extending through the interior of the assembly. A fluiddelivery tube may be deployed within a conduit for circulating fluidthrough the assembly, such as heated air or water for regulating thetemperature or other physical characteristics of the assembly.

The invention comprises both single construction panels and constructionassemblies formed from two or more panels.

BRIEF DESCRIPTION OF DRAWINGS

In drawings which describe embodiments of the invention but which shouldnot be construed as restricting the spirit or scope thereof,

FIG. 1 is an exploded, isometric view of two mating construction panelsconfigured in accordance with the invention.

FIG. 2 is an isometric view of the construction panels of FIG. 1 in anassembled configuration.

FIG. 3 is an exploded, isometric view of multiple bottom constructionpanels aligned adjacent one another and showing a single top panel.

FIG. 4 is an isometric view of the assembly of FIG. 3 showing the panelsassembled together with the top panel in an overlapping orientation.

FIG. 5 is an isometric view similar to FIG. 4 showing multiple toppanels.

FIG. 6 is an isometric view similar to FIG. 4 showing multiple top andbottom panels coupled together.

FIG. 7 is an exploded, isometric view similar to FIG. 3 showing thebottom panels arranged in an elongated pattern and showing a single toppanel.

FIG. 8 is an isometric view of the assembly of FIG. 7 showing the panelsassembled together with the top panel in longitudinal alignment with thebottom panels.

FIG. 9 is an isometric view similar to FIG. 8 showing two top panels.

FIG. 10( a) is an isometric view of an assembly comprising multipleconstruction panels coupled together and showing fluid delivery tubesextending through conduits defined within the interior of the assembly.

FIG. 10( b) is an isometric view of the assembly of FIG. 10( a) showingthe fluid delivery tubes in a different direction.

FIG. 11 is a plan view of a first surface of a single constructionpanel.

FIG. 12 is a plan view of a second surface of a construction panel.

FIG. 13( a) is a first end elevational view of the panel.

FIG. 13( b) is a second end elevational view of the panel.

FIG. 14( a) is a first side elevational view of the panel.

FIG. 14( b) is a second side end elevational view of the panel.

FIG. 15 is an exploded, end isometric view of two mating constructionpanels configured in accordance with the invention.

FIG. 16 is an isometric view showing the first surface of a singleconstruction panel.

FIG. 17 is an isometric view showing the second surface of a singleconstruction panel.

FIG. 18 is an enlarged, top plan view of the first surface of the panelsimilar to FIG. 11.

FIG. 19 is an enlarged, top plan view of a second surface of the panelsimilar to FIG. 12.

FIG. 20( a) is a first side elevational view of a single panel.

FIG. 20( b) is a second side elevational view of a modified embodimentof the panel.

FIG. 21( a) is a first end elevational view of single panel.

FIG. 21( b) is a second end elevational view of a single panel.

FIG. 22 is an exploded, end isometric view of two mating constructionpanels configured in accordance with an alternative embodiment theinvention.

FIG. 23 is an isometric view showing the first surface of a singleconstruction panel of FIG. 22.

FIG. 24 is an isometric view showing the second surface of a singleconstruction panel of FIG. 22.

FIG. 25 is an enlarged, top plan view of the first surface of the panelof FIG. 22.

FIG. 26 is an enlarged, top plan view of a second surface of the panelof FIG. 22.

DESCRIPTION

Throughout the following description, specific details are set forth inorder to provide a more thorough understanding of the invention.However, the invention may be practiced without these particulars. Inother instances, well known elements have not been shown or described indetail to avoid unnecessarily obscuring the invention. Accordingly, thespecification and drawings are to be regarded in an illustrative, ratherthan a restrictive, sense.

This application relates to a multi-purpose construction panel 10. Inthe illustrated embodiment panel 10 is generally rectangular in shape.As shown in FIGS. 1 and 2, each panel 10 may be matingly engaged withanother panel 10 to form an assembly 12. As shown in FIGS. 3-9, and asdescribed in further detail below, a plurality of panels 10 may bealigned in a desired configuration and releasably coupled together toform assemblies 12 of different sizes and shapes.

Each panel 10 has a first side 14 and a second side 16. As shown inFIGS. 11 and 18, for example, first side 14 may comprise a planar decksurface 18 interrupted by a plurality of channels 20. Optionally, aplurality of small apertures 22, which extend between sides 14,16, maybe spaced within channels 20. The orientation of the channels 20 may bearranged to form a decorative pattern on first side 14. For example,channels 20 may subdivide deck surface 18 into a plurality ofquadrilateral or triangular shaped deck segments. In alternativeembodiments, side 14 may consist of a flat continuous sheet or othershapes or patterns could be substituted.

Panel second side 16 is subdivided into a plurality of compartments 24by wall partitions 26, as shown in FIGS. 12, 17 and 19 for example. Inthe illustrated embodiments, compartments 24 are square or rectangularin shape. A plurality of cylindrical female sleeves 28 and male sleeves30 are disposed within compartments 24. In the illustrated embodimentmale sleeves 30 have a smaller diameter and larger height than femalesleeves 28. More particularly, sleeves 30 project from compartments 24to a greater extent than sleeves 28. When a pair of panels 10 arecoupled together as shown in FIG. 2, the second sides of the respectivepanels 10 matingly engage such that each male sleeve 30 on one panel 10is received within a corresponding female sleeve 28 on the other panel10, and vice versa.

As best shown in FIGS. 12, 17 and 19, each compartment 24 may be furthersubdivided by wall partitions 32 into subcompartments 34. In theillustrated embodiment each compartment 24 is divided into 4subcompartments 34. Each wall partition 32 is connected to andstructurally supports a sleeve 28, 30. A small cylindrical guide tube 36may be disposed within each subcompartment 34. Each tube 36 may beconnected to a corresponding sleeve 28, 30 by means of a flange 38. Asdescribed further below, tubes 36 may function as guides for receivingfasteners used to couple mating panels 10 together. As described below,the fasteners (not shown), are insertable into tubes 36 throughapertures 22 which are aligned therewith.

The bottom or innermost surface 40 of panel second side 16 is generallyflat. However, as best shown in FIGS. 17 and 19, surface 40 may compriseelongated ribs 42 which define the channels 20 of panel first side 14,as described above.

As shown, for example, in FIG. 15, some wall partitions 26 and 32comprise linearly aligned notches 44 formed in edge portions thereof. Inthe illustrated embodiment, each notch 44 has a semi-circular orquarter-circular profile. As shown best in the end elevational views ofFIGS. 13( a),(b) and 21(a), (b), wall partitions 26 and 32 havingnotches 44 with a quarter-circular profile may be located at the edgesof panel 10 (i.e. where a panel 10 may be arranged to abut another panel10). When a mating pair of panels 10 are coupled together to form anassembly 12 with the second side 16 of each panel facing inwardly, thenotches 44 of each panel 10 are aligned and together define acylindrical conduit 46 extending through the interior of assembly 12(FIG. 2). Likewise, when four or more panels 10 are grouped together toform larger structures, conduits 46 may be defined at the joinderbetween adjacent pairs of assemblies (FIGS. 10( a) and 10(b)). As shownin FIG. 10( a), each conduit 46 may receive a fluid delivery tube 48,for example for circulating anti-freeze, heated air or other fluidthrough each assembly 12. Other filaments may also be disposed inconduits 46, such as cables for use in securing a large number ofassemblies 12 together. Optionally, as shown in FIG. 10( b), tubes 48 orother filaments may be deployed in each assembly 12 in a transverserather than longitudinal direction (that is, tubes 48 may extend in adirection perpendicular to the direction shown in FIG. 10( a)).

A plurality of construction panels 10 may be conveniently coupledtogether to form assemblies 12 having many different possible shapes andsizes. As shown in FIGS. 3-9, multiple panels 10 forming a base portionmay first be aligned adjacent one another, each with their first side 14facing downwardly on a support surface and their second side 16 facingupwardly. A plurality of mating panels 10 forming a top portion, eachwith their second side facing downwardly and their first side facingupwardly, may then be placed on the aligned base panels 10. As shown inFIGS. 3-6, each top panel 10 may be positioned so that it overlapsmultiple base panels 10 to bind the base panels 10 together.Alternatively, each top panel 10 may be positioned so that it is alignedwith only a single corresponding base panel 10, as shown in FIGS. 2,10(a), 10(b) and 15.

As will be appreciated by a person skilled in the art, although theterms “base” and “top” have been used in the example above, assembly 12may be configured in many different orientations. For example, sinceeach panel 10 of assembly 12 is identical in this embodiment, and henceassembly 12 is symmetrical, assembly 12 may be flipped 180 degrees sothat the “top” panels form part of the base and vice versa. Further,assemblies 12 may be oriented vertically, for example as part of a wallstructure, or in other non-horizontal orientations.

Once panels 10 have been assembled as desired to form assembly 12,panels 10 may be secured together with fasteners. For example, bolts(not shown) may be inserted through selected apertures 22 on one side ofassembly 12 and into tubes 36. Once they are fully inserted, bolts maybe secured, such as with nuts, on the opposite side of assembly 12.

In some applications it may be desirable that assembly 12 befluid-impervious. For example, in chemical warehouses and the like itmay be important that flooring be impervious to fluid chemicals toprevent soil and groundwater contamination. In such applications,grooves 20 on panel first surfaces 14 may be filled with caulking orother sealants after panels 10 have been fastened together. In otherembodiments, panels 10 may be manufactured with no apertures 22 or withonly a small number of apertures 22 necessary to secure panels 10together. This would avoid the need to seal unfilled apertures 22.

In other applications, it may be important that a large number ofapertures 22 remain open after assembly 12 is assembled and deployed.For example, assembly 12 may be used in applications, such as temporarywalkways, where it is desirable to avoid collection of water on thesurface thereof. In such applications water can be collected withinchannels 20 and drain through tubes 36 into the ground or other supportsurface underlying assembly 12. Apertures 22 also enable any water orwater vapour within the interior of assembly 12 to escape to thesurrounding environment. This may be important in northern climateshaving frequent freeze/thaw weather cycles.

Construction panels 10 may be formed from molded plastic or otherlight-weight materials in one embodiment of the invention. By way ofnon-limiting example, each panel 10 may be 32″×48″ in size have athickness of approximately 2″. In this example, each compartment 24 isapproximately 8″×8″ in size and each longitudinally extending conduit 46(FIG. 10( a)) is approximately 16″ apart. A plastic panel 10 having theabove dimensions weighs on the order of about 20 pounds and maytherefore be easily lifted and carried by a single person for ease ofinstallation. This enables convenient assembly or disassembly of panels10 by ordinary consumers without the need for cranes or other heavylifting machinery.

Construction panels 10 may be used to form assemblies 12 useful in awide variety of applications. For example, assemblies 12 may be used inflooring, roofing and wall construction applications in both indoor andoutdoor environments. By way of non-limiting examples, assemblies 12 maybe used in walkways, roadways, parking lots, driveways, decking androofing. In some applications, assemblies 12 may be mounted on top ofexisting structures, such as decking joists or beams, or may be coveredby other materials, such as roofing materials. Since panels 10 arelightweight and easy to handle, and relatively inexpensive tomanufacture and transport, they will be useful in many consumerapplications. Other potential consumer and industrial applications forconstruction panels and the like are described in the applicant'sco-pending U.S. application Ser. No. 11/689,409 filed 21 Mar. 2007entitled MULTI-PURPOSE CONSTRUCTION MODULE which is hereby incorporatedby reference in its entirety.

As described above, assemblies 12 may be deployed in applications whereit is desirable to regulate the temperature or other physicalcharacteristics thereof. For example, heated assemblies 12 may be usedas temporary driveway covers in winter months to prevent snow and iceaccumulation. The temperature of assemblies 12 may be regulated bycirculating fluids in a flow path through the interior of each assembly12. For example, as shown schematically in FIG. 10, in one embodiment ofthe invention a heat-regulating or heat exchanging fluid may becirculated through tubing 48 deployed within conduits 46. As used inthis patent application, the term “fluids” includes both liquids andgases. For example, the fluid may be water heated by a boiler (notshown) in fluid communication with tubing 48. In another embodiment ofthe invention, the fluid may be anti-freeze. In yet another embodiment,gases could be circulated within conduits 46, such as heated air. Theboiler may include a fluid pump or, alternatively, a pump may beinstalled at another location in the flow path As is well known in theprior art, the fluid pump may include a timer or other controller tooperate only during selected intervals rather than continuously.

By way of further example, assemblies 12 may be connected to form panelssuitable for use as heated flooring, roofing or wall panels. Forexample, heated flooring, walls or roofing comprising constructionpanels 10 could be used in barns, stables, greenhouses, storage sheds orother temporary structures where it is important to control indoortemperature or avoid snowfall or ice accumulation. As indicated above,other materials could be placed over assemblies 12 such as dirt, mulch,bedding, rubber matting, styrofoam or other roofing materials, dependingupon the particular application.

As indicated above, assemblies 12 could be temporarily installed inoutdoor parking lots, driveways, roadways and the like to melt snowduring winter months in northern climates. Assemblies 12 could similarlyused on roofing to reduce or prevent snow accumulation. Assemblies 12could be configured so that they are heated only during particularclimatic conditions or during particular times of day. At the end of thewinter season the panels 12 could be quickly and easily disassembled andremoved if desired.

Depending upon the application and range of operating temperatures, thedistance between conduits 46 could be adjusted. For example, in verycold conditions the number of conduits 46 carrying heated water in tubes48 could be increased to reduce the distance between adjacent conduitsand ensure that the entire assembly 12 is evenly heated. As will beappreciated by a person skilled in the art, in alternative embodimentsof the invention the flow path of conduits 48 could also be varied (e.g.by using non-linear flow paths) to achieve substantially even heating orto suit particular applications.

As will be appreciated by a person skilled in the art, constructionpanels 10 may be formed in many different shapes and sizes. For example,in addition to rectangular shapes, panels 10 could be constructed inhexagonal, pentagonal or other geometric shapes or combinations thereof.

A further embodiment of the invention is in FIGS. 22-26. In thisembodiment a tube 36 a may be located in each sleeve 28 and 30. Asdescribed above, panels 10 may be coupled together to form an assembly12 with each male sleeve 30 inserted into a corresponding female sleeve28. Panels 10 may then be secured together with fasteners such as boltsinserted through selected apertures 22 on one side of assembly 12 andinto tubes 36 a (instead of, or in addition to, tubes 36). Once they arefully inserted, bolts may be secured, such as with nuts, on the oppositeside of assembly 12. Each panel may also include notches 22 asurrounding an aperture 22 on first side 14 to accommodate a bolt head,nut or washer. This ensures that end portions of the fastener will beflush or recessed relative to deck 18.

In the embodiment of FIGS. 22-26 additional flanges 38 may be providedfor structurally supporting tubes 36 and 36 a. For example, as shownbest in FIG. 26, each tube 36, 36 a may be supported by four separateflanges 38.

As will be apparent to those skilled in the art in the light of theforegoing disclosure, many alterations and modifications are possible inthe practice of this invention without departing from the spirit orscope thereof. Accordingly, the scope of the invention is to beconstrued in accordance with the substance defined by the followingclaims.

What is claimed is:
 1. A system comprising a plurality of constructionpanels, each construction panel having a first side and a second sideand a side wall extending between said first side and said second sideat the perimeter of said panel, said side wall comprising a pair ofopposed longitudinal side portions and a pair of opposed transverse sideportions, wherein said first side comprises a substantially planar deckand said second side comprises: (a) a plurality of first wall elementsdefining a plurality of compartments therebetween; and (b) a pluralityof open-ended sleeves each located in one of said compartments, whereinsaid sleeves comprise a first group of female sleeves having a firstheight and a second group of male sleeves having a second heightexceeding said first height, wherein said male sleeves of a first one ofsaid panels are sized to fit within said female sleeves of a second oneof said panels when said first one of said panels and said second one ofsaid panels are releasably connected to form an assembly, wherein saidfemale and male sleeves are arranged within said compartments in analternating array, wherein said female and male sleeves alternateregularly in said array in both longitudinal and transverse directions,wherein said first one of said panels and said second one of said panelsare releasably and securely connectable in said assembly in either analigned configuration or an offset configuration, wherein in saidaligned configuration said side wall of said first one of said panels isaligned with said side wall of said second one of said side panels andin said offset configuration said side wall of said first one of saidpanels is at least partially misaligned with said side wall of saidsecond one of said panels.
 2. The system as defined in claim 1, whereinsaid first side is located directly opposite said second side andwherein said deck has a plurality of spaced-apart channels formedtherein, each of said channels having a length extending on said firstside.
 3. The system as defined in claim 2, wherein said channelssubdivide said deck into a plurality of quadrilateral or triangularshaped deck segments.
 4. The system as defined in claim 2, comprising aplurality of spaced-apart apertures extending through said panel betweensaid first and second sides.
 5. The system as defined in claim 4,wherein said apertures are located in said channels.
 6. The system asdefined in claim 1, wherein said sleeves are cylinders each having anopen end at a location furthest from said deck.
 7. The system as definedin claim 6, wherein said female sleeves have a diameter exceeding adiameter of said male sleeves.
 8. The system as defined in claim 1,wherein said first wall elements have a height substantially the same assaid first height.
 9. The system as defined in claim 1, wherein each ofsaid compartments is further subdivided into a plurality ofsubcompartments defined by a plurality of second wall elements, each ofsaid second wall elements extending between one of said first wallelements and one of said sleeves.
 10. The panel as defined in claim 9,comprising a plurality of guide tubes, wherein each of said guide tubesis located within one of said subcompartments.
 11. The system as definedin claim 10, comprising a plurality of spaced-apart apertures extendingthrough said panel between said first and second sides, wherein each ofsaid guide tubes is aligned with one of said apertures.
 12. The systemas defined in claim 11, wherein each of said guide tubes furthercomprises a support rib connecting said tube to a corresponding one ofsaid sleeves.
 13. A construction assembly comprising at least twoconstruction panels as defined in claim 1 extending in parallel planesand coupled together, wherein said second side of one of said panelsreleasably engages said second side of another one of said panels. 14.The assembly as defined in claim 13, wherein said assembly comprises afirst group of said panels arranged adjacent one another with said firstand second sides in alignment and extending in a first one of saidparallel planes and a second group of said panels arranged adjacent oneanother with said first and second sides in alignment and extending in asecond one of said parallel planes, wherein said second sides of saidfirst group of panels engages said second sides of said second group ofpanels, wherein at least some of said panels in said second groupoverlap multiple panels in said first group to connect said multiplepanels together.
 15. The assembly as defined in claim 13, wherein, ineach of said panels, each of said of said compartments is furthersubdivided into a plurality of subcompartments defined by a plurality ofsecond wall elements, each of said second wall elements extendingbetween one of said first wall elements and one of said sleeves.
 16. Theassembly as defined in claim 15, wherein each of said panels comprises aplurality of guide tubes, wherein at least some of said guide tubes arelocated within a corresponding one of said subcompartments.
 17. Theassembly as defined in claim 16, wherein said guide tubes of said one ofsaid panels is aligned with said guide tubes of said another one of saidpanels.
 18. The assembly as defined in claim 17, comprising a pluralityof spaced-apart apertures extending through each of said panels betweensaid first and second sides thereof, wherein each of said guide tubes isaligned with an aligned pair of said apertures.
 19. The assembly asdefined in claim 18, wherein at least some of said guide tubes arelocated within said male and female sleeves.
 20. The assembly as definedin claim 19, further comprising support flanges connected to said guidetubes.
 21. The assembly as defined in claim 19, further comprisingnotches surrounding at least some of said apertures on said first sideof said panel.
 22. A construction assembly comprising at least twoconstruction panels coupled together, wherein each panel has a firstside and a second side, wherein said first side comprises asubstantially planar deck and said second side comprises: (a) aplurality of first wall elements defining a plurality of compartmentstherebetween; and (b) a plurality of sleeves each located in one of saidcompartments, wherein said sleeves comprise a first group of femalesleeves having a first height and a second group of male sleeves havinga second height exceeding said first height, wherein said male sleevesof one of said panels are sized to fit within said female sleeves ofanother one of said panels, wherein said female and male sleeves arearranged within said compartments in an alternating array, wherein saidfemale and male sleeves alternate in said array in both longitudinal andtransverse directions, wherein said second side of one of said panelsreleasably engages said second side of another one of said panels,wherein said assembly comprises a first group of said panels arrangedadjacent one another with said first and second sides in alignment andextending in a first plane and a second group of said panels arrangedadjacent one another with said first and second sides in alignment andextending in a second plane parallel to said first plane, wherein saidsecond sides of said first group of panels engages said second sides ofsaid second group of panels, wherein at least one of said panels in saidsecond group overlaps multiple panels in said first group to connectsaid multiple panels together.